VALVEWORKS USA OPERATION AND SERVICE MANUAL FOR 7
Contents
1. H 4 ASSEMBLY INSTRUCTIONS ESEC du EUREN VEN Eng 5 BODY SUB ASSEMBDLY uoo aen ese vocosesedesevsesveesseovsbsvesosdbuoo Se Vo NER SES 5 1 2 BONNET SUB ASSEMBLY eo va vi on oo ea eoo ooa 09 60600 00 cove 9 6089 Pa Vaes eo PE 89 899 6 60600 7 1 3 8 2 5 0 5 215 2 994 0 996 969045906690 6 090409 690 860609 69006 0 060489 99909 8 90490 8008 694804 9 5 50552055 co once E E 12 8 PC Eo 13 PHYSICAL DIMENSIONS 14 PERIODIC MAINTENANCE ssssssssssscssssscscccecscsscsscccccecsesssscececeecsessescececcesesscscececcsssesssscecccsscesesssscssecsecessessees 15 MAINTENANCE 15 STEM BEARING LUBRICATION is es ov oaov sa oval or no Ga so aU s Vo ae nU so Uo so al ro Vo ae o nea reo vea a V oua ue 15 BODY LUBRICATION 16 PLASTIC INJECTION PACKING sivvsssesvcceuscoudecuevouccsusdeuecovevonscouecouevcveveuevousvevevovevouscousvouevevevensvousvevevovevensvosssonevevees 17 INSTALLING INJEC2. After coating the threads and screwing in the Using a stud tightening nut and a studs the body should appear as shown above certified torque gun tighten the studs NOTE The above shown pictures can be used as an illustration to better understand the assembly of lower bonnet 1 2 BONNET SUB ASSEMBLY The bonnet assembly parts Install a thrust bearing onto the are shown above threaded end of the stem as shown NOTE HIGH TEMPERATURE PACKING IS USED FOR THE EXAMPLE BUT REGULAR PACKING IS INSTALLED IN A SIMILAR FASHION Install the packing retainer bushing over Place the packing over the threaded the threaded end of the stem as shown end of the stem as shown above Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 VALVEWORKS USA Model FM 4 Operation Manual Wrap the stick packing around the threads Add second thrust bearing around stem and insert the above the stem packing and insert the threaded bearing spacer sleeve as shown into the top of the end into the bonnet bonnet Insert the Bearing Retainer Nut and The bearing retainer nut should appear as tighten with an expanding wrench shown above Insert the Bearing Retainer Locknut and Insert the alemite grease fitting tighten it with an expanding wrench as well The finished bonnet assembly should appear similar to the one s
3. Any Special Test Requirements Any Special Material Requirements Any Special Coating or Protection Requirements Other Specifications and or Certifications VVVVVVVVVVV The model 4 is full bore 7 1 16 API 6A gate valve Using a standard hand wheel operation the result is a high torque operation The operating torque can be seriously reduced to half by using a Ball screw operator which is readily available as an upgrade for the Model FM4 OPERATION Valveworks USA Model FM 4 Expanding Gate and FM 4 Slab Gate valves are generally hand wheel operated The expanding gate of the MODEL FM 4 Valve consists of two pieces major and minor acting one against the other by means of a dual wedge expanding when the valve is either fully closed or fully opened The expansion effect of the wedge against the seats through the parallel faces of the gate provides a strong and positive seal against pulsations and vibrations created by flow conditions The MODEL 4 slab gate valve is one piece slab gate that uses two floating seats to generate a highly reliable seal The slab gate eliminates the chance of trapping pressure within the body cavity which can cause pressure locking 1 Fully open the valve before installing or shipping The sealing area of the gates in the full open position is protected by the body and is less likely to be damaged 2 Do not remove the molybdenum disulfide coating from internal parts This coating serves as a lubrica
4. may require more or less maintenance than this manual suggests For more information contact Valveworks USA TROUBLESHOOTING Problem Cause Solution Disconnect from service and replace the seats Leakage when open thru Bonnet Seal Disconnect from service and replace body bonnet connection Ring the bonnet seal ring Leakage when partially open thru Disconnect from service and replace Packing top of bonnet the packing ee eee Flange Seal Disconnect from service and replace Ring the flange seal ring For extra assistance with these or any other problems please contact Valveworks USA Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 V ALVEWORKS USA Model FM 4 Operation Manual TEST PROCEDURE 1 Grease and insert the ring joint 2 Be sure that the test flange has a tightened grease into one of the body flanges fitting all of its studs and a hex nut on each stud with the hex nuts on the grease fitting side as shown NOTE YOU CAN FIND THE FLANGE RING JOINT SIZE IN THE PHYSICAL DIMENSIONS SECTION OF THIS MANUAL 3 Align the test flange studs with the body 4 Place the test flange on the valve flange flange holes Then push the test flanges its with all of the studs going thru the valve studs and their hex nuts onto the body flange flange holes a
5. reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 22 V ALVEWORKS USA Model FM 4 Operation Manual Pass a drift mandrel through the valve bore Remove one of the cap and attach a flow after the valve has been assembled line from the grease pump to the grease operated and pressure tested fitting as shown above Remove the lower bonnet grease fitting cap and After the valve is accepted it is tagged with attach a pressure release tool as shown above a green or blue tag before being painted Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 V ALVEWORKS USA Model FM 4 Operation Manual VISUAL INSPECTION Before installing a Valveworks USA Model 1540 valve in the field here are a few items to visually inspect 1 Be the Upper bonnet grease 2 Be sure the lower bonnet grease fitting cap is on and tight fitting cap is on and tight 3 Make sure the Alemite fittings are 4 Make sure the Handwheel Nut is tight on and tight NOTE THE GLAND BACKSEAT WILL BE SCREWED INTO THE FINISHED VALVE Make sure the gate is in the open position Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318
6. sediment and other foreign matter which tend to accumulate in the valve body A regular draining program will increase the life of a valve against damage caused by 1 Water freezing in the body cavity causing damage to the body Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 V ALVEWORKS USA Model FM 4 Operation Manual 2 An accumulation of foreign matter in the lower part of the body which could prevent the valve from fully closing resulting in a throttling action which may cause inefficient sealing 3 Foreign matter trapped in the body may become lodged between the sealing surfaces of the gate and seats resulting in scored or damaged sealed 4 Venting a Model M amp MSG valve is a positive method of checking the sealing ability of the gate and seats If the body vents down to zero pressure with the valve in fully closed position this is definite indication that sealing surfaces are in good condition PROCEDURE TO VENT OR DRAIN 1 Place the valve gate in a fully opened or fully closed position 2 Remove the safety cap from either body grease fitting and attach the pressure release tool CAUTION Remove the safety cap slowly to allow the ball check to sufficiently seal to avoid uncontrolled venting Should the ball check fail to seal properly pressure will continue to blow through the safety cap ori
7. 425 0934 24 VALVEWORKS USA Model FM 4 Operation Manual FIELD HOOK UP INSTRUCTIONS is Grease and insert the ring joint into Align the service flange holes with the body one of the body flanges flange holes Push a stud thru each aligned hole until there is a stud thru each hole Screw a hex nut on both sides of each stud by hand NOTE YOU CAN FIND THE FLANGE RING JOINT SIZE IN THE PHYSICAL DIMENSIONS SECTION OF THIS BOOKLET Tighten the service flange hex nuts A finished flange should appear as with an certified torque gun shown REPEAT STEPS 1 4 FOR THE OPPOSITE FLANGE Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 25
8. 6NM 9 STELLITE 6 9A PLASTIC 9B STELLITE 3 PHYSICAL DIMENSIONS 9A Model FM 4 Operation Manual COATING NONE PHOSPHATE MOLY STANDARD PAINT COATING POWDER COAT NITRIDE QPQ PHOSPHATE EXCEPTION FC BODY BUSHING DO NOT NITRIDE HARDFACE STELLITE 6 SPRAY amp FUSE HARDFACE TUNGSTEN CARBIDE HARDFACE COLMONOY 5 ELECTROLIS NICKEL WELD ON HARDFACE ZINC PLATE XYLAN COATING 4130 INCONEL 625 CLAD 4130 SS 316 RING GROOVE Dimensions 2000 psi 3000 psi 5000 psi 26 1 8 28 1 18 32 7 1 16 7 1 16 7 1 16 16 5 8 16 5 8 16 5 8 34 34 34 24 24 30 15 15 15 All dimensions inches Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 14 VALVEWORKS USA Model FM 4 Operation Manual PERIODIC MAINTENANCE The Model M amp MSG gate valves are non lubricated sealed valves in that they do not require the injection of lubricants or sealants to effectively seal However to prevent corrosion excessive wear and ensure continued operation a normal amount of lubrication is recommended to extend the life and serviceability of the valve MAINTENANCE TOOLS To perform normal maintenance and lubrication the following tools are recommended 1 Grease pump
9. C 75 F to 250 F The Model FM 4 gate valves covered in this manual are suitable for performance requirement levels 1 and 2 and 2 respectively TEMPERATURE RATING Temperature Operating Range classification TRIM CHART Minimum Material Requirements Material class Body bonnet end and Pressure controlling parts outlet connections stems and mandrel hangers AA General service Carbon or low alloy steel Carbon or low alloy steel BB General service Carbon or low alloy steel Stainless steel CC General service Stainless steel Stainless steel DD Sour service Carbon or low alloy steel b Carbon or low alloy steel 3 Sourservice Carbon or low alloy steel P Stainless steel FF Sour service Stainless steel Stainless steel HH Sour service 5 CRAs As defined by NACE MR 0175 b In compliance with NACE MR 0175 Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 VALVEWORKS USA Model FM 4 Operation Manual ORDERING INFORMATION The following information should be provided with any request for quote or order placement of Valveworks USA Model FM 4 gate valves Model of Valve Size of Valve Pressure Rating maximum API 6A Requirements PR PSL API 14D Requirements Class of Service Temperature Rating API 6A Material API 6A
10. TING 1 7 101 0001 BODY GREASE FITTING 2 8 034 57 STEM 1 9 089 FM4 5700 PACKING SET CHEVRON V 1 082 0000 PACKING INJECTION 1 9b 055 5700 PACKING INJECTION SLEEVE 1 10 206 57 BONNET LOWER 1 11 096 5700 STUD amp NUT LOWER 16 12 071 57 BONNET SEAL RING LOWER 1 13 052 52 PACKING RETAINER BUSHING 1 14 002 57 GATE SLAB 1 15 110 57 THRUST BEARING 2 16 031 57 1 SEAT ASSEMBLY 2 16a TEFLON INSERT 2 16b O RING BACKSEAL 2 17 060 57 GATE GUIDE 2 18 135 5700 HANDWHEEL 1 19 135 5700 HANDWHEEL NUT 1 20 135 5700 HANDWHEEL WASHER 1 21 155 57 BEARING HOUSING 1 22 032 3291 WEATHER SEAL O RING 1 23 990 0007 NAME PLATE 1 24 GREASE FILL 25 041 57 DRIVE NUT 1 The last two digits in the part no s vary with X Material Type and Y Coating The table below gives the different available material types and coatings Please refer to the valve tag to see the material type and coating on the valve parts Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 13 VALVEWORKS USA X MATERIAL TYPE 1 4130 1A 4140 1B 1040 1C 1018 1D 1020 1E SA285 C 1F 1026 2 41055 FORGED 2A 542400 3 17455 50 4 316SS 4A 316 304SS 4B 30458 5 BRONZE 6 INCONEL 718 INCONEL 725 6B INCONEL X750 1 MONEL 8 A487 4D 8A A487 4C 8B CA15 8C CF8M 8D CF3M 8E CA
11. TION PACKING Fano Vine ngon v Co Fa 17 PROCEDURE TO VENT OR DRAIN aeuo ree re ea o UE VEU PK SU VP ad VV VE 17 MAINTAINANCE INTERVALS EE VEU EE RU ad s erae Vua CE Keg 17 TROUBLESHOOTING isess cs svscseceacecsaccstcoveccavecteccevectecsescssesocnceseseonsesesecseceonsusecoavesvascoueeteceevesseseaueesecdecest 19 TEST PROCEDURE 15 2 1 HYDROSTATIC 2 5 21 222 HYDROSTATIC SEAT TEST vcctccccssccccsesccsdsouscossdosscocdseessosvdesscecdseuscovedess covadeuscosvceuecessseueossedouecousceussouvconssesscs 22 VISUALINSPECTION ec 24 FIELD HOOK UP INSTRUCT IONS ccccssssssscsssssssssccccescscessenceccssssssssecccesescessenececcesscscssenscesssssssscecscessscscess 25 Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 VALVEWORKS USA Model FM 4 Operation Manual APPLICATIONS Valveworks USA Model FM 4 gate valves can be applied to the following sizes and working pressures APPLICATION OPTIONS AVAILABLE Gate valve size 7 1 16 Valve working pressure 2000 5000 psi Temperature range 60 C to 121
12. V ALVEWORKS USA OPERATION AND SERVICE MANUAL FOR 7 1 16 2 5 MODEL 4 GATE VALVES MODEL 4 7 1 16 2 5 M MODEL FM 4 7 1 16 2 5 M SLAB GATE VALVE EXPANDING GATE VALVE VALVEWORKS USA Model FM 4 Operation Manual INTRODUCTION In appreciation to our customer for purchasing our product we have prepared this Operation Manual to assist you in the Operation Maintenance Assembly and Installation of the Valveworks USA API 6A 7 1 16 Model FM 4 gate valves We encourage you to follow recommendations in this booklet to attain the best possible service from our product which is designed and proven to offer the service one can expect of a quality product If you need to contact a representative for more specific information pertaining to a special problem please contact VALVEWORKS USA 1650 SWAN LAKE RD BOSSIER CITY LA 71111 PHONE 318 425 0266 FAX 318 425 0934 TOLL FREE 888 425 0266 EMAIL SALES VALVEWORKSUSA COM WEBSITE WWW VALVEWORKSUSA COM CONTENTS APPLICA TIONS covasssis cise cassestcsscasvasceceossetesncoesstaecessseen soceeossncesectcuseesossecoageesese ssscsscesecesssoevessuce sucssvsneteseete c cosssaceseusess ces 3 TEMPERATURE RATING 262022204250 raa ro vi cossssvensvaceoscecusosseveselsecssesduconsecodcesvcouecov sosbectsscevesochestsseuscesveosoess 3 TRM CHAR d 52555 M 3 ORDERING INFORMATION 4 OPERA TION J
13. caused by throttling through a valve by leakage of a closed valve or by Leakage through the stem packing Valves in service on gas containing hydrates or in fresh water service exposed to low external temperatures may also iced up In this case it is advisable to inject alcohol or glycol into the valve body through the drain fitting to combat these conditions The same procedures are used for injecting alcohol or glycol as are used for valve body lubrication Do not operate the valve immediately after injecting as these fluids should be retained in the body to perform the Antifreeze effect Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 18 VALVEWORKS USA Model FM 4 Operation Manual IDENTIFICATION PLATE Identification plates are attached to all Valveworks USA API Production Gate Valves They are located on the bonnet of each valve and warrants that all products are manufactured to design and quality control specifications of industry standards The information listed on the identification plate should be referred to when ordering replacement parts MAINTENANCE INTERVALS Procedure Recommended Interval Vent or Drain See Page 8 Cycle Open to Close Semi Annually Disconnect amp Test Annually These are just recommended intervals of maintenance Depending on the level of usage your valve s
14. exceed the maximum working pressure of the valve being lubricated PLASTIC INJECTION PACKING Plastic packing is added to the stuffing box through the plastic injection fitting on the valve bonnet to further energize the packing around the stem shutting off package leakage There are different types of plastic packing depending on service and temperature Packing is available in 3 8 X 1 9 5 mm X 25 4 mm sticks to be injected through the packing fitting on the valve bonnet Packing fittings used on Model M amp MSG valves are 1 2 12 7 mm 14 NPT standard thread connection This fiting is equipped with a safety ball check which allows the insertion of plastic packing without special adapters or tools Stick packing can be added through the packing fitting with the valve under pressure The valve may be installed in any position INSTALLING INJECTION PACKING 1 Run the 3 4 hex head screw all the way into the fitting and then back out slowly observe the bleeder hold in the packing fitting If no pressure or plastic packing is observed flowing out through this hole this would indicate that the ball check has seated At this point the packing screw can be removed 2 Apply one stick at a time until the leak has stopped Apply only as much packing as needed to stop the leak Excessive packing pressure will cause the stem to bind and will make operation of the valve difficult Most products contain a certain amount of water lime scale
15. fices You should then retighten the safety cap screw and vent through the other body grease fitting Once the body pressure is bled to zero you should then attempt to repair the leaking ball check 3 Screw the stem of the releasing tool into the fitting forcing the ball check off its seat The valve will vent and drain once the ball check is unseated A program of regular draining and body venting is the most positive way to prevent problems caused by foreign matter in the valve However if a regular draining program cannot be followed it is recommended that valves be drained after the following operations 1 After a well has come in and has been cleaned up 2 After a mudding operation 3 After a cementing operation 4 Anytime the valve seems hard to operate by hand and will not fully open or close by the required number of handwheel turns 5 When the valve is hard to operate from the fully open or fully closed position because it is pressure locked or Iced up Pressure locked is a condition that may exist with any dual seat expanding type gate valve when body pressure greatly exceeds line pressure It occurs only in fully closed position and is a positive indication that sealing surfaces are in good condition Iced up is a condition caused by a restriction in the flow or a differential in the pressure of gas flow at high pressure which produces extremely low temperatures These restrictions or differentials in pressure may be
16. he procedure begins with the assembly of the lower bonnet to the body Apply anti seize compound to the body threads and screw the studs into them Using a certified torque gun tighten the studs and nuts on the body side Insert a lower bonnet seal ring and then the bonnet and tighten the nuts on the bonnet side Body seat gate and gate guides are shown in Grease the back side of the seat as shown the figure above The above figure is used for illustration purpose only T 4 Insert the greased side into the body cavity as Grease and insert the second seat as shown shown Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 VALVEWORKS USA Model FM 4 Operation Manual 1 Insert the gate assembly into the valve The gate segment should point in the same direction of between the seats and in the gate guides the flow as shown above For expanding gate type only NOTE Model MSG slab gates are bidirectional and can be inserted with either side facing the flow The gate should be between the seats and Place the bonnet seal ring in the bonnet inside the gate guides as shown above seal ring groove as shown above Ew y Coat all of the body threads with anti Screw one stud into each of the seize compound as shown above holes as shown above VALVEWORKS USA Model FM 4 Operation Manual
17. hown above Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 Model FM 4 Operation Manual VALVEWORKS USA 1 3 FINAL ASSEMBLY Grease the tip of the threaded end Place the greased end into the gate of the stem with a No 3 grease with the bonnet holes aligned with as shown above the body studs as shown above Place a hand wheel onto the stem and When the bonnet is lowered remove rotate the handwheel clockwise to lower the handwheel The final assembly the bonnet onto the body should appear as shown NOTE VALVEWORKS USA ALWAYS ALIGNS BODY AND BONNET GREASE FITTINGS AS SHOWN ABOVE Screw a hex nut onto each stud by hand The body grease fittings and their safety caps Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 VALVEWORKS USA Model FM 4 Operation Manual The packing injection fitting for Screw one of the body grease fittings into the bonnet either of the grease fitting holes on the body SE Screw the remaining grease fitting into Tighten one of the grease the remaining hole on the body fittings with a certified torque Tighten the remaining grease fitting Place the valve on the ground with a certified torque gun for stability T
18. ighten each of the body bonnet At this point the assembly should hex nuts with a certified torque appear similar to the one above 10 VALVEWORKS USA Model FM 4 Operation Manual Screw a safety on one of the Then screw the remaining safety cap Body grease fittings onto the remaining body grease fitting Screw the packing injection fitting Tighten the packing injection into the bonnet fitting with a certified torque gun Place the handwheel onto the stem and The final assembly should appear secure it with a handwheel nut The handle similar to the one above should point up as shown 11 V ALVEWORKS USA Model FM 4 Operation Manual ASSEMBLY DRAWING 2 COO LOOSE Y MODEL M VW DB SG 3000 5000 LB W P 7 1 16 SLAB GATE HANDWHEEL OPERATED OPERATION BI DIRECTIONAL SLAB GATE TO OPEN AND CLOSE BACKOFF HANDWHEEL 1 4 TURN Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 VALVEWORKS USA Model FM 4 Operation Manual BILL OF MATERIALS ITEM PART NO DESCRIPTION QUANTITY 1 235 57XY DB BODY 1 2 205 57 BONNET UPPER 1 3 096 5700 STUD amp NUT UPPER 16 4 070 57 BONNET SEAL RING UPPER 1 5 109 0001 GREASE FITTING ALEMITE 1 6 105 0001 PACKING INJECTION FIT
19. lease tool and the valve The hydrostatic body test pressure shall be determined by the rated working pressure of the equipment Hydrostatic test pressures shall be as given in Table 1 HYDROSTATIC BODY TEST PRESSURE PSI MPa Working End and Line Pipe Pressure Outlet and Tubing Rating PSI Mpa Connections PSI Mpa Threads PSI Mpa 2 000 13 8 4 000 27 6 4 000 27 6 3 000 20 7 6 000 41 4 6 000 41 4 5 000 34 5 7 500 51 7 7 500 51 7 10 000 69 0 15 000 103 4 15 000 103 4 15 000 103 4 22 500 155 2 20 000 138 0 30 000 207 0 2 2 HYDROSTATIC SEAT TEST A With the valve closed apply the rated working pressure B Hold and monitor at that pressure for at least three 3 minutes C Open the valve and bleed off the pressure until it s reduced to zero Then close the valve and the pressure release tool D Repeat steps A C Switch the sides of your flow and pressure release connections bleed off the new pressure release side and repeat steps A D to perform a seat test on the new flow side The valve is acceptable if no leakage is visible during the holding period While holding the hex nuts on the body flange loosen each of the test flange hex nuts with a certified torque gun After removing the body flange hex nuts you can remove the test flange its studs and their hex nuts Proprietary Booklet of Valveworks USA Do not
20. nt and corrosion inhibitor 3 To hydrostatically test the valve body to full API test pressure the valve must be in a partially open position When testing the valve in the closed position seat test do not exceed the working pressure stamped on the valve identification plate 4 During storage always leave the valve in fully opened or fully closed position This will tightly wedge the gate and segment against the seats and prevent damage to the sealing area of both the gate and seats 5 When lubricating the body do not exceed the maximum API working pressure stamped on the identification plate The valve should be fully closed or fully opened during lubrication of the body or seats 7 Seat lubrication pressures should not exceed the maximum allowable API test pressure The expanding gate design of our Model M valves provides a tight mechanical positive seal however to properly effect this seal the valve must be fully opened or fully closed in order to wedge the gate and segment against Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 V ALVEWORKS USA Model FM 4 Operation Manual the seats Do not back off the hand wheel 8 This method of operation will prevent damage to the sealing surfaces of the gate and seats and will increase the life of the valve ASSEMBLY INSTRUCTIONS 1 1 BODY SUB ASSEMBLY T
21. roduct flowing through the valve Approximately one pound of grease per inch of nominal valve bore size is sufficient to provide adequate lubrication Place the valve in the fully opened or fully closed position before lubricating the valve 1 Remove the safety caps from 2 Install the grease gun fitting with both safety ball check fittings gauge on either of the grease fittings 3 Install the pressure release tool on the other grease fitting A 1 2 NPT 10 000 psi W P needle valve may be attached to the outlet of the pressure release tool as a safety measure should the ball check not hold pressure Open 1 2 needle valve rotate handle of pressure release tool clockwise until main stem makes contact with the ball check unseat same to release existing body pressure Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 16 V ALVEWORKS USA Model FM 4 Operation Manual If the body pressure does not bleed down completely the volume of the pressure released can be controlled with the pressure release tool Continue injecting grease into the body through the other grease fitting After lubrication reinstall the two safety caps and operate the valve several times and return to desired position CAUTION During pressurized valve body lubrication pressure applied to the valve body with the grease gun must not
22. s shown 5 Screw the each hex nut on the vacant side 6 Hammer the hex nuts on the test of a stud as shown until all of the studs have flange side until they are tight a nut on the test flange and the valve flange Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 20 VALVEWORKS USA Model FM 4 Operation Manual 7 A finished flange should appear as shown REPEAT STEPS 1 7 FOR THE OPPOSITE FLANGE Remove the safety cap from one of the test Remove the grease fitting cap from the flange grease fittings and attach a pressure opposite test flange and attach the flow release tool as shown above line as shown above 2 1 HYDROSTATIC BODY TEST With the pressure release tool and flow line connection tight open the valve partially and apply the test pressure for at least three 3 minutes Bleed off the pressure until it s reduced to zero and close the pressure release tool Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 21 VALVEWORKS USA Model FM 4 Operation Manual Raise the pressure back up to the test pressure for the secondary pressure holding period of at least three 3 minutes Bleed off the pressure until it s reduced to zero Then close the pressure re
23. with adapter 2 Safety pressure releasing tool and coupling Valveworks USA API Gate Valves 2000 PSI W P thru 5 000 PSI W P are supplied with 1 2 NPT body fitting connections STEM BEARING LUBRICATION Valveworks USA API valves are equipped with alemite hydraulic type 1 8 NPT bonnet grease fittings Stem bearing lubrication is accomplished through this fitting using a standard type grease gun Any good grade No 3 grease is recommended for this lubrication Stem bearings normally do not require great amounts of grease An example of using a grease gun to grease the stem bearings If too much lubrication should occur excess grease will flow around the stem to the atmosphere Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 15 V ALVEWORKS USA Model FM 4 Operation Manual CAUTION IF BEARINGS NEED TO BE CHANGED THE VALVE MUST BE REMOVED FROM SERVICE BODY LUBRICATION Valves may require body lubrication if they become hard to operate or when they are used in corrosive service conditions For this purpose each valve has two safety ball check fittings located at the bottom and top of the body of the valve Valveworks USA recommends its OEM grease as standard however any good grade 3 4 or 5 grease is recommended for body lubrication but caution is to be taken so as not to use soluble grease near the p
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